Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO-CRIMPER* III Hand Crimping
Tool Assembly 58596-1 with 408-4348
L C B
1 of 5
E 2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. ther products, logos, and company names used are the property of their respective owners.
T LING ASSISTANCE CENTER 1-800-722-1111
PR DUCT INF RMATI N1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
04 JUN 09 Rev A
Die Assembly 58596-2
PROPER SE G IDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Stationary Jaw
Back of Tool
(Wire Side)
Pivot Pin
The PR -CRIMPER III Hand Crimping Tool Assembly is a Commercial"
grade tool and is designed primarily for field installation, repair, maintenance
work, or prototyping in industrial, commercial, or institutional applications.
Product crimped with this tool will meet the crimp height requirement for hand
tools in the appropriate 114 series specification, but may not comply with other
feature parameters of the specification. Tyco Electronics offers a variety of
tools to satisfy your performance requirements. For additional information,
contact the Tooling Assistance Center at 1-800-722-1111.
PR -CRIMPER III Hand
Crimping Tool Frame
354940-1 (408-9930)
Stationary Handle
Moving Handle
Locator Assembly
(Supplied with
Die Assembly)
Front of Tool
(Locator Side)
Die Assembly
Guide Contact
Moving Jaw
Ratchet Adjustment Wheel
TE Die
TE Locator
Contact
Wire
TE Di
e
Assembly
TE L
oca
t
or
Assembly {
C
on
t
ac
t
Family }
Size
(mm2)Insul Dia
(mm [in.]) Strip Length (mm [in.])
58596-2 58515-5 Power Quadlok
Seal 4.0 4.09
[.161] 4.83 - 5.59 [.190 - .220]
{ Supplied with die assembly, also available separately. } Contact the Tooling Assistance Center or Product
Information Center (see below) or specific contact part
numbers.
Figure 1
1. INTROD CTION
PRO–CRIMPER III Hand Crimping Tool Assembly
58596–1 consists of Die Assembly 58596–2 and
PRO–CRIMPER III Hand Crimping Tool Frame
354940–1. The die assembly consists of crimping
dies and a locator assembly.
Read these instructions thoroughly before crimping
any contacts.
Reasons for revision can be found in Section 11,
REVISION SUMMARY.
Dimensions on this sheet are in millimeters [with
inch equivalents provided in brackets]. Figures
and illustrations are for identification only and are
not drawn to scale.
NOTE
i

408-4348
PRO-CRIMPER III Hand Crimping Tool Assem ly 58596-1
Rev A2 of 5 Tyco Electronics Corporation
Figure 2
Nut Locator
Asse bly Tool Fra e
Die Retaining Pins
Die Retaining Screws
Cha fer
Insulation Anvil
Wire Anvil
Offset
Wire Cri per
Cha fer Insulation
Cri per
Guide Contact
2. DESCRIPTION (Figures 1 and 2)
The tool features a tool frame with a stationary jaw
and handle, a moving jaw, a moving handle, and an
adjustable ratchet that ensures full contact crimping.
The tool frame holds a die assembly with one
crimping section.
The die assembly features a wire anvil, an insulation
anvil, a wire crimper, and an insulation crimper.
Attached to the outside of the frame is a locator
assembly, which contains a locator, a spring retainer,
and a contact support.
Attached to the outside of the movable jaw is a
contact guide. Die retaining pins and die retaining
screws are used to position and secure the dies in the
tool frame. Nuts are used on the upper die and
movable jaw retaining screws to hold the locator
assembly and contact guide in place.
3. INSTALLATION AND REMOVAL OF DIE SET
AND LOCATOR ASSEMBLY
(Figure 2)
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the wire anvil and insulation anvil so that
their chamfered sides and their marked surfaces
face outward, when mounted in the moving jaw of
the tool frame.
3. Insert the two long die retaining pins.
4. Insert the die retaining screw through the jaw
and through both anvil dies, and tighten the screw
just enough to hold the dies in place. Do
not
tighten the screw completely at this time.
5. Place the wire crimper and insulation crimper so
that their chamfered sides and their marked
surfaces face outward, when mounted in the
stationary jaw of the tool frame.
6. Insert the two short die retaining pins.
7. Insert the die retaining screw through the jaw
and through both crimper dies, and tighten the
screw just enough to hold the dies in place. Do
not
tighten the screw completely at this time.
8. Carefully close the tool handles, making sure
that the anvils and crimpers align properly.
Continue closing the tool handles until the ratchet
in the tool frame has engaged sufficiently to hold
the anvils and crimpers in place, then tighten both
die retaining screws.
9. Place the locator assembly over the end of the
long screw, and position the locator assembly
against the side of the tool jaw.
10. Place the nut onto the end of the long screw
and tighten the nut enough to hold the locator
assembly in place, while still allowing the locator to
slide up and down.
11. Place the contact guide over the retaining
screw and the two pins.

408-4348
PRO-CRIMPER III Hand Crimpin Tool Assembly 58596-1
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Tyco Electronics Cor oration
12. Secure the contact guide to the movable jaw
with a nut. Do not tighten the nut completely at this
time.
13. Place a contact in the anvil and adjust the
contact guide to fit the contact.
14. When contact guide is correctly positioned,
tighten the nut.
15. To disassemble, close the tool handles until the
ratchet releases, remove the nut, the locator
assembly, the two die retaining screws, and the
four die retaining pins, and slide the anvils and
crimpers out of the tool jaws.
4. CONTACT SUPPORT ADJUSTMENT (Figure 3)
The contact support s preset pr or to sh pment,
but m nor adjustment may be necessary.
1. Make a sample crimp and determine if the
contact is straight, bending upward, or bending
downward.
2. If adjustment is required, loosen the screw that
holds the contact support onto the locator
assembly.
The ratchet has detents that create aud ble cl cks
as the tool handles are closed.
3. Place a contact with wire into the proper nest
and close the tool handles until the ratchet reaches
the sixth click, or until the contact support touches
the contact.
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
5. Move the contact support as required to
eliminate the bending of the contact.
6. Tighten the nut and close the handles until the
ratchet releases.
7. Remove and inspect the contact.
8. Make another sample crimp. If the contact is
straight, tighten the contact support screw. If the
contact is still being bent during crimping, repeat
the adjustment procedure.
5. CRIMPING PROCEDURE
Th s tool s prov ded w th a cr mp adjustment
feature. Int ally, the cr mp he ght should be
ver f ed as spec f ed n F gure 4. Refer to Sect on
6, CRIMP HEIGHT INSPECTION, and Sect on 7,
RATCHET ADJUSTMENT, to ver fy cr mp he ght
before us ng the tool to cr mp des red contacts
and w re s zes.
Refer to the table in Figure 1 and select wire of the
specified size and insulation diameter. Strip the wire
to the length indicated in Figure 1, taking care not to
nick or cut wire strands. Select an applicable contact
and identify the appropriate crimp section according
to the wire size markings on the tool. Refer to
Figure 3 and proceed as follows:
Figure 3
Adjustment
Screw for
Contact
Su ort
Contact
Su ort Locator
Back of Tool
(Wire Side)
Wire
Contact
(Ty )
Locator in
Wire Sto Slot Wire
Inserted
to Sto
Stri
Length
Wire
Seal
Wire Seal
Contact
Guide
NOTE
i
NOTE
i
NOTE
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408-4348
PRO-CRIMPER III Hand Crimping Tool Assembly 58596-1
Rev A4 of 5 Tyco Electronics Corporation
1. Hold the tool so that the back (wire side) is
facing you. Squeeze tool handles together and
allow them to open fully.
2. Holding the contact by the mating end, insert the
contact — insulation barrel first — through the front
of the tool and into the appropriate crimp section.
3. Position the contact so that the mating end of
the contact is on the locator side of the tool, and so
that the open “U” of the wire and insulation barrels
must face the top of the tool. Place the contact up
into the nest so that the movable locator drops into
the slot in the contact. Refer to Figure 3. Butt the
front end of the wire barrel against the movable
locator.
Make sure that both sides of the insulation barrel
are started e enly into the crimping section. Do
NOT attempt to crimp an improperly positioned
contact.
4. Hold the contact in position and squeeze the
tool handles together until ratchet engages
sufficiently to hold the contact in position. Do NOT
deform insulation barrel or wire barrel.
5. Insert stripped wire, with wire seal, into contact
insulation and wire barrels until it is butted against
the wire stop, as shown in Figure 3.
6. Holding the wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open and remove crimped contact.
The crimped contact may stick in the crimping
area, but the contact can be easily remo ed by
pushing downward on the top of the locator (see
Figure 3).
7. Check the contact’s crimp height as described in
Section 6, CRIMP HEIGHT INSPECTION. If
necessary, adjust the crimp height as described in
Section 7, RATCHET ADJUSTMENT.
6. CRIMP HEIGHT IN PECTION
Crimp height inspection is performed through the use
of a micrometer with a modified anvil, commonly
referred to as a crimp–height comparator. Tyco
Electronics does not manufacture or market
crimp–height comparators. Detailed information on
obtaining and using crimp–height comparators can be
found in instruction sheet 408–7424.
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed.
2. Refer to Section 5, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
Position Point
on Center of
Wire Barrel
Opposite
Seam
A"
Modified Anvil
WIRE IZE CRIMP ECTION CRIMP HEIGHT
DIM.
(
A
)
AND
mm2(MAX) (WIRE IZE MARKING)
()
TOLERANCE
+.05 [+.002]
4.0 4.0 2.34
[.092]
Figure 4
3. Using a crimp height comparator, measure the
wire barrel crimp height as shown in Figure 4. If the
crimp height conforms to that shown in the table,
the tool is considered dimensionally correct. If not,
the tool must be adjusted. Refer to Section 7,
RATCHET ADJUSTMENT.
7. RATCHET (Crimp Height) ADJU TMENT (Fi ure 5)
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel
from the locator side of the tool.
Figure 5
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)
CAUTION
!
NOTE
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408-4348
PRO-CRIMPER III Hand Crimpin Tool Assembly 58596-1
5 of 5Rev A
Tyco Electronics Corporation
3. Observe the ratchet adjustment wheel. If a
tighter crimp is required, rotate the adjustment
wheel COUNTERCLOCKWISE to a
higher–numbered setting. If a looser crimp is
required, rotate the adjustment wheel
CLOCKWISE to a lower–numbered setting.
4. Replace the lockscrew.
5. Make a sample crimp and measure the crimp
height. If the dimension is acceptable, replace and
secure the lockscrew. If the dimension is
unacceptable, continue to adjust the ratchet, and
again measure a sample crimp.
8. MAINTENANCE
Ensure that the tool and dies are clean by wiping
them with a clean, soft cloth. Remove any debris with
a clean, soft brush. Do not use objects that could
damage the tool. When not in use, keep handles
closed to prevent objects from becoming lodged in
the crimping dies, and store in a clean, dry area.
9. VISUAL INSPECTION
The crimping dies should be inspected on a regular
basis to ensure that they have not become worn or
damaged. Inspect the crimp sections for flattened,
chipped, worn, or broken areas. If damage or
abnormal wear is evident, the tool must be replaced.
See Section 10, REPLACEMENT.
10. REPLACEMENT
Customer–replaceable parts are shown in Figure 1.
Available separately, PRO–CRIMPER III Hand
Crimping Tool Repair Kit 679221–1 includes a
replacement nut and a variety of pins, rings, screws,
and springs.
If the dies are damaged or worn excessively, they
must be replaced.
Order the repair kit and replaceable parts through
your Tyco Electronics representative, or call
1–800–526–5142, or send a facsimile of your
purchase order to 1–717–986–7605, or write to:
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS
PO BOX 3608
HARRISBURG PA 17105–3608
11.REVISION SUMMARY
Revisions to this instruction sheet include:
S PRO–CRIMPER II Hand Tool became the
PRO–CRIMPER III Hand Tool;
S The TE logo was applied; and
S the format was updated to the current
corporate requirements.